Download 8" MPV User`s Manual for end port

Wave Cyber (Shanghai) Co., Ltd.
8” End Port Membrane Housing User’s Guide
If you want to get more information of Wave Cyber Products, please visit our website
http://www.wave-cyber.com
Page 1
CONTENTS
SECTION 1
OPERATION AND MAINTENANCE GUIDE ………………… 11
SECTION 2
PIPING CONNECTIONS……………………………………….. 13
SECTION 3
ELASTICITY AND MOUNTING REQUIREMENTS………… 14
SECTION 4
INSTALLATION GUIDE………………………………………
15
—
MOUNTING SHELL…………………………………..
—
ELEMENT LOADING ………………………………… 17
—
MOUNTING HEAD ASSEMBLY……………………
19
—
REMOVING HEAD ASSEMBLY……………………
12
SECTION 5
SUITABILITY FOR INTENDED USE………………………
14
SECTION 6
SAFETY………………………………………………………
15
SECTION 7
TROUBLESHOOTING………………………………………
16
SECTION 8
MEMBRANE HOUSING ASSEMBLY DRAWING……….
17
SECTION 9
(HIGH FLOW) PRESSURE DROP TEST GRAPH…………
18
Page 2
15
SECTION 1
OPERATION/MAINTENANCE GUIDE
WAVE-150E-8 WAVE-250E-8 WAVE-300E-8 WAVE-400E-8 WAVE-450E-8 WAVE-600E-8 WAVE-1000E-8 WAVE-1200E-8
.150
250
.300
.400
.450
.600
.1000
.1200
.PSI
PSI
.PSI
.PSI
.PSI
.PSI
PSI
PSI
DANGER - High Pressure Device
This vessel may cause loss of life, severe bodily harm, and/or property damage
if not correctly installed, operated and maintained. Read and understand all
guidelines given before attempting to open, service or operate this vessel.
Failure to follow these guidelines and observe every precaution may result in
malfunction and could result in explosive head failure.
Misuse, incorrect assembly or use of damaged or corroded components can
result in explosive release of the end closure.
We recommend that only qualified mechanics, experienced in servicing high
pressure hydraulic systems, open, close and service this vessel.
This section is a guide to proper operation and maintenance of Wave Cyber
pressure vessel series. Good industrial practice must be used in applying this
information to assure safe vessel use. These guidelines are not intended to relieve
the user from full responsibility for correct operation and maintenance of the
vessels.
For technical specifications and dimensions, refer to the Engineering Drawing
of each specific model.
The information in all sections must be carefully followed for the vessel to
provide the safe, long service life for which it is designed.
Page 3
Proper vessel handling and installation are important to safe use and long vessel
life. These guidelines should be followed carefully; however, they do not relieve the
purchaser from full responsibility for proper inspection, handling and installation.
Damage due to improper handling or installation is the sole responsibility of the
purchaser.
Improper assembly, misuse or corrosion damage can result in mechanical failure,
property damage and serious injury or death. Read and follow all instructions
carefully. Pay particular attention to the safety precautions given in this Operation
/Maintenance Guide section. Should any information in this guide not agree with the
system supplier’s instructions, call Wave Cyber for clarification.
Corrections or recommendations for improvement of this manual should be
addressed to:
Wave Cyber (Shanghai) Co., Ltd.
No. 2, Songchun Road, Qingpu Industries Zone,
Qingpu District, Shanghai, China
Post Code: 201703
Tel: 86-21-69758588
Fax: 86-21-69758288
http://www.wave-cyber.com
Page 4
SECTION 2
PIPING CONNECTIONS
The following are suggested guidelines to ensure that the vessel is allowed to expand
and is easily serviced.
1.
Support the header and interconnecting piping in a manner that they are
self-supporting relative to the vessel.
2.
Connecting piping alignment to feed, Concentrate and Permeate ports should
not exceed 0.7 mm misalignment (Figure 1). If the misalignment exceeds 0.7
mm, please contact Wave Cyber for technical assistance.
3.
Piping connections to the vessel’s feed/concentrate ports should be via
flexible Victaulic® couplings. To get maximum flexibility, install two
Victaulic® couplings on each Feed/Concentrate port of the vessel.
Figure 1
Page 5
SECTION 3
ELASTICITY AND MOUNTING REQUIREMENTS
Mounting design must allow for vessel expansion, both axially and radially. Although
the expansion under pressure is slight, undue restriction can result in damage to the
vessel and to other system components. Expansion is typically up to 0.8mm/m in
diameter and up to 0.4mm/m in length. A six-element vessel, for example, would
expand approximately 4.5mm in length. The following suggestions will help to ensure
the vessel is allowed to expand and will ease servicing.
1. Mount the vessel on the urethane support pads furnished. Do not mount directly to
any rigid structure.
2. Use the stainless steel straps furnished. Straps should be tightened sufficiently to
hold the vessel on the urethane support pads, but not so tightly as to restrict
expansion. A torque of 25-50 in-lbs. (11.3-22.7kgs) is sufficient.
3. U-bolts should not be used for vessel mounting under any circumstances.
4. Provide a flexible piping connection to permit decoupling the header from the
vessel. The recommended Permeate Port connection is a U-bend pipe with flexible
connections at each end, or a flexible hose. Recommended Feed and Concentrate
connections are via two flexible Victaulic® couplings.
5. Do not hard plumb any piping connections to the vessel.
6. Support the header independently. Piping should be self supporting or supported
by the headers.
7. Include an expansion loop in the branch connection to allow for:
A. Elastic growth under pressure.
B. Thermal growth in vessel length.
8. The total weight of branch connection and fittings supported by the vessel should
not exceed 2 kg for the Permeate ports and 4 kg for the Feed/Concentrate for
Wave Cyber series vessels.
The above suggestions are intended to help prevent damage in typical applications.
Unusual or special applications may involve other considerations, to be determined by
the system designer.
Page 6
SECTION 4
INSTALLATION GUIDE
A. Mounting Shell
This section is concerned with the mounting of Wave Cyber Series pressure vessels.
These guidelines must be integrated with any additional procedures required for your
specific installation.
Installation Guidelines:
1.
Provide adequate room for servicing at both ends of vessel. Elements are
installed from the upstream end (feed), pushed through towards the
downstream end (concentrate) and, eventually, removed from the downstream
end.
2.
Follow the procedures in Section 3-Elasticity and Mounting Requirements.
NOTE
It is important that each vessel be placed to minimize any strain on
piping/tubing that connects a vessel to a header. Normally each vessel
should be centered in the frame with the feed and concentrate ports
positioned such that piping/tubing connections can be made easily, without
undue strain at each end of the vessel.
3.
Mount vessels on urethane saddles (provided with the vessel) positioned in
line with pre-drilled frame holes. For -1 through -3 vessels, holes for the
mounting straps should be drilled at approximate center span 'S' (Figure 2).
For -4 and -8 vessels, holes for the mounting straps should be drilled at span
'S' from the middle of the vessel and a third saddle, without a strap, should be
placed at mid span (Figure 3). These dimensions are shown on the
corresponding engineering drawing.
Figure 2
Page 7
Figure 3
4.
Connect the vessel to piping manifolds while adjusting the position of the
shell and piping manifolds. Try to align the feed port and concentrate port.
The distance between the vessel and piping manifolds should be set as 3 mm
(Figure 4). Try to align in all directions. The Victaulic® coupling should be
able to be tightened without applying any adhesive on it. Lock the vessel and
piping manifolds in place only after all alignment procedures are finished.
Figure 4
Warning
DO NOT MOUNT VESSEL RIGIDLY. RESTRICTED EXPANSION
CAN RESULT IN DAMAGE TO THE VESSEL. SEE ELASTICITY
AND MOUNTING REQUIREMENTS SECTION FOR FURTHER
DETAILS.
DO NOT TIGHTEN THE NUTS OVERLY, OTHERWISE THE VESSEL
MIGHT GET DAMAGED.
Page 8
5. Place mounting straps over vessel.
6. Provide adequate room for servicing at both ends of vessel. Elements are
installed and removed in the direction of feed flow.
7. Position screw through the frame mounting holes into strap nuts and run up to the
frame finger tight.
8. Connect vessel feed piping
9. Using a wrench, tighten mounting bolts one additional full turn. This should
result in 25-50 in-lbs. (11.3-22.7kgs) of torque.
NOTE
Straps are designed to secure the vessels during operation. They are not
designed to handle all loads that might occur during shipment. Appropriate
vessel restraint should be employed considering such factors as the mode of
shipment, distance to be traveled and the design of the system. The vessels
and frame should be blocked to prevent any differential movement which
could be caused by the forces experienced during shipment.
B. Element loading
1. Examine the inside diameter of the vessel for scratches or imperfections that may
affect sealing capability of head or element seals. Corrosion deposits or other
foreign matter, including any excess lubricant, should be removed.
2. Flush out the vessel with clean water to remove all dust and debris.
3. Examine membrane element surfaces for any imperfection which could scratch
the vessel bore. Pay particular attention to edges of anti-telescope device
(ATD/brine seal carrier). If any defects are found which can not be easily fixed,
please contact element supplier for solution.
4. Using an approximate 50% mixture of glycerine in water, lubricate the inside of
the vessel. This may best be accomplished using a suitably sized swab soaked in
the mixture. This procedure will ease membrane element loading and reduce
chance of scratching the vessel bore. (Note: Standard O-Rings are EPDM and it is
recommended that oil based lubricants NOT to be used with EPDM.)
5. Load the first element into the upstream end of the vessel. Leave a few inches of
the element projecting from the vessel to facilitate interconnection to the next
element.
6. Apply a light film of a non-petroleum based lubricant, such as glycerin, to the
inter-connector O-ring. (The amount of lubricant should be just enough to give a
lustre to the O-ring. Excess glycerin must be removed to prevent possibility of
element contamination).
7. Assemble the inter-connector to the loaded element.
8. Line up the next element to be loaded and assemble it to the inter-connector
already assembled on first element.
Page 9
NOTE
Take care to avoid pushing elements too far as it can be difficult to push the
stack in a reverse direction.
9. Push both elements into the vessel until a few inches are projecting from the
vessel. Repeat loading process until all elements are installed.
10. When the final element is installed, push the element stack forward until the
distance between the first (downstream) element and retaining ring groove is
about 170 mm. (Figure 5.)
Element
Adaptor
Warning
Connect the central (permeate)
tube of the membrane element
stack, with an adapter on each
end, to the permeate port in the
head at both ends of vessel.
Pressurizing vessel without both
adapters installed could result in
explosive head failure.
Figure 5
Mounting element interface hardware
1. Put the adaptor/membrane PWT seal on the adaptor first.
2. Then install the adaptor into the membrane permeate tube.
Minimize the Gap between element and vessel
PVC washers should be used to minimize the gap before pressurizing (Figure 6). This
is done to prevent the element from being damaged by movements inside the vessel.
CAUTION
Gap
Excess gap inside the vessel
may cause damage to the
element in operation.
Adaptor
PVC wacher
Figure 6
Page 10
C. Mounting Head Assembly
Step 1 Inspect Shell Inside Surface
1. Inspect the vessel inside surface for any corrosion deposits or other foreign matter.
If any are found, clean the surface as follows:
A. Using a mild soap solution, clean each end of the vessel liner surface up to
300 mm from each end of vessel.
B. Rinse away all loosened deposits from the shell inside surface using clean
fresh water.
2. Inspect the vessel inside surface for scratches or other damage which could cause
leaks. Vessels that leak must be replaced.
3. Inspect Feed/Concentrate port seals and attachments for internal and external
damage or deterioration.
NOTE
CAUTION
Contact Wave Cyber for guidance, if
damage to the vessel's internal surface or
Feed/Concentrate port, seals or attachments
is discovered during inspection.
Never attempt to repair a
fiberglass shell.
Step 2 Set Up Head Assembly
1. Place the adaptor/permeate port seal into permeate port seal groove located on
inside of permeate port.
1) Check to make sure adaptor
O-ring is in place inside the
permeate port.
2) Secure the thrust cone in position
on the permeate/seal plate.
PWT Seal
2. Attach the thrust cone onto the down stream permeate port.
Warning
Install the thrust cone on the down stream. If the thrust cone is not
installed on the correct position, serious damage may be caused.
Page 11
Step 3 Head Seal and Head Lubrication
1. Ensure that the head seal is covered with a thin layer of lubricant and is free from
any dirt or dust contamination.
2. Then lubricate the whole head seal and the area where it will contact the head seal.
Note
Note
Lubricate the seal with a little
Non-Petroleum based lubricant, such
as glycerin or other suitable silicon
based lubricant. (Glycerin is a
commercially available lubricant that
will not foul membranes.)
In some installations it may be
advisable
to
tighten
a
system-required permeate port
nipple or fitting into the
Permeate port before the head
is assembled into the vessel.
Step 4 Install Head
1. Holding the head square to the axis of the shell, slowly push the head into the
shell until the seal passes the retaining ring groove and a slight resistance is felt.
2. As a resistance is felt, two hands may be required. Push the head into shell until
the head clears the retaining ring groove. Head can be tapped lightly with a rubber
mallet if necessary to seat the head into position.
Step 5 Install Interlock
1. Carefully wipe out any debris or moisture from the retaining ring groove. The
groove must be clear and dry before proceeding.
2. With the head assembly installed in shell, place the tip of the head retaining ring
in the stainless steel groove (The non bent tab end).
3. Begin pushing the retaining ring into
the groove as you rotate your hand
around the I.D. of the shell.
Page 12
4. Continue until the entire
retaining ring is installed
in the groove.
5. Verify that the retaining
ring is fully seated in the
groove before proceeding.
Step 6
Connect Permeate Piping
1. Connect manifold piping to the vessel Permeate port.
NOTE
Using teflon tape or anaerobic sealant on all NPT and BSPP threaded connections
will help ensure a leak-free assembly. Union fitting does not require teflon tap or
anaerobic sealing.
WARNING
Don’t overly tighten the thread, excessive force may cause the permeate port to
crack.
Step 7 Pre-pressure Check
It is vitally important that the following checks be carried out before any attempt is
made to pressurize the vessel.
a. Head Assembly
Verify the following at each end of the vessel:
1. Head assembly is in good condition, with no evidence of damage or corrosion.
2. Retaining ring is properly in place.
b. Membrane Elements
Verify that...
1. Elements are installed in the vessel.
2. Element adapters are installed at each end of vessel.
3. Thrust cone is installed at downstream end of vessel.
c. Piping Connections
1. Check all piping connections to ensure that they will provide a leak-free seal.
Page 13
Step 8 Pressurization
1. After following the above
pre-pressurization checks, pressurize
vessel in accordance with element
manufacturer’s specifications.
2. Vessels should be filled slowly to
assist trapped air in escaping.
Warning
DO NOT PRESSURIZE THE
VESSEL UNTIL ELEMENTS
AND THE RETAINING RING
ARE PROPERLY INSTALLED.
3. Vessels should be pressurized slowly to avoid damage to membrane elements and
vessel components.
D．Removing Head Assembly
Step 1 Relieve pressure
1. Shut off all sources of pressure and relieve pressure from the vessel, following the
system manufacturer’s recommendations.
Step 2 Disconnect Permeate port
1. Disconnect and remove permeate piping from the permeate port of the vessel.
Step 3 Examine end closure
1. Examine end closure of vessel for corrosion. If any is evident, proceed as follows:
A. Loosen any deposits.
B. Flush away loosened deposits with clean water.
Step 4 Remove Retaining ring
Remove the retaining ring from the stainless steel groove inside the shell.
Following is the procedure: Use a tool with a peaked head (such as pliers) and
insert the peaked head into the hole on the head of the retaining ring. Raise the head
of the retaining ring and move it out of the stainless steel groove (Figure 7). Pull the
head of the retaining ring slightly out of the stainless steel groove with the left hand,
meanwhile; rotate the retaining ring clockwise with the right hand until the entire
retaining ring is pulled out of the stainless steel groove Take care to avoid hitting or
levering against the vessel, as this could result in delamination.
Hole
Figure 7
Page 14
Step 5 Remove head
1. Add extension to permeate port or use head puller.
2. Pull the head assembly all the way out of the vessel.
Note
It may be necessary to rock the head slightly and/or tap the head inboard to
break head seal bond. See trouble shooting section for more information.
Page 15
SECTION 5
SUITABILITY FOR INTENDED USE
Wave Cyber MPV pressure vessels are designed for continuous, long-term use as
housings for reverse osmosis membrane elements. Models are available for 150, 300,
450, 600 and 1000 PSI. The allowable temperature is -7℃~49℃. Any make of eight
inch nominal diameter spiral wound element is easily accommodated.
The filament wound FRP shell is composed of continuous fiber glass impregnated
with heated epoxy resin system. The allowable water PH range is 3-10 under normal
operating conditions and 2-12 if the vessel is periodically cleaned. Cleaning agents
must be wiped off and cleaned from the vessel after periodical cleaning. For the
material list of vessel, refer to the Engineering Drawing of each specific model.
In an RO system there is considerable potential for explosive head failure, which
could result in serious injury or loss of life. All decisions as to suitability for use must
include full consideration of the various safety aspects involved. These include, but
are not limited to:
• Process fluid compatibility (e.g. chemical and temperature considerations).
• External environmental factors (e.g. corrosive atmosphere; remote or special
environments where plastics might be undesirable; etc.).
• Abnormal back pressure which might result in pressurizing permeate port above
125 PSI (alternate materials are available).
• Capability of the user to maintain vessel properly.
• Requirement for increased fire resistance in some circumstances (e.g. may
preclude use of PVC for permeate ports).
Use of a Wave Cyber pressure vessel for other than its intended application will void
the warranty.
Wave Cyber will assist the purchaser in determining the suitability of the standard
vessel for their specific operating conditions. For non-standard applications, alternate
materials are available on special order. The final determination, however, including
evaluation of the standard materials of construction for compatibility with the specific
environment, is the responsibility of the purchaser.
Page 16
SECTION 6
SAFETY
Safety in service of fiberglass pressure vessels depends on proper application,
installation, operation and maintenance. This section is intended to provide guidance
towards safe system design. The safety information given in the Installation Guide
section should also be studied and used appropriately in conjunction with the
precautions listed below.
Design Considerations for Safety
Fluid Compatibility
The materials of construction selected must be compatible with the process fluid and
with proposed preserving and cleaning fluids. Standard materials are listed on the
engineering drawings. In cases where the standard materials are unacceptable, suitable
alternates may be available.
Pressure and Temperature Design Limits
Operation of a vessel outside its design limits will void the warranty and could result
in vessel fatigue with possible eventual explosive head failure. Although each Wave
Cyber MPV pressure vessel is tested to design pressure, long term operation above
design pressure must be prevented. Permeate port pressure must not exceed 125 Psi
(with standard materials). Vessels should not be continuously operated at
temperatures above 120°F without Wave Cyber’s specific permission.
Over-pressure Protection
It is essential that over-pressure protection be provided such that the pressure to which
any vessel is subjected cannot exceed 105% of design pressure.
Mounting
The pressure vessel should not be used as a support. Piping manifolds and other
fittings should be supported by properly designed system framework. Operating
personnel should be discouraged from applying undue force to any fittings connected
directly to a pressure vessel.
Accessibility
Pressure vessels should be positioned within the system such that elements can be
inserted at the upstream end and removed from the downstream end (i.e. elements are
installed and removed in the direction of feed flow).
Page 17
SECTION 7
TROUBLESHOOTING
Problem
1. The head leaks
when testing
pressure
2. Sudden Drop in
Permeate
Quality
3. The adaptor
cracks during
installation
4. The retaining
ring can not be
removed after
being used for
some time
Possible Cause
a. Dust or dirt on the inside
surface of the vessel,
b. Inside surface of the
vessel get damaged;
c. Head seal gets damaged;
d. The water temperature
exceeds the max.
operating temperature of
the vessel.
a. Element connecting pipe
seal gets damaged;
b. Permeate port seal gets
damaged;
c. Adaptor seal gets
damaged.
a. Installation sequence is
not correct;
b. The installation is not
performed following
procedure,
a. The retaining ring is
seriously deformed after
being used for a long
time.
5. The head can not
a. The head seal gets
be removed after
deformed and corroded
being used for
seriously.
some time.
Page 18
Solution
a. Remove the head and clean the
dust and dirt;
b. Contact Wave Cyber for
assistance;
c. Replace the seal;
d. Lower the water temperature
to below the max. operating
temperature with auxiliary
equipment.
a. Replace element connecting
pipe seal;
b. Replace permeate port seal;
c. Replace adaptor seal.
a. Insert the adaptor into the
element first, then install the
head assembly;
b. For correct procedures, see
Section 4. 3.4.2;
a. Try soaking with a mold
release agent or rust remover
in the connecting area of the
retaining ring and hit slightly
with handle of a screwdriver or
other tools so as to hit it off.
a. Remove permeate port pure
water pipe connecting head.
Insert an iron rod (o.d.=20)
into the permeate port water
outlet pipe for about 150 mm
and tap the rod back and forth
slightly (take care not to hit the
element) until the head is
removed.
b. You can also use a head puller
tool to remove the head.
Page 19
9
8
7
6
11
SECTION 8. Membrane Housing Assembly Drawing
5
4
10
3
2
1
2
3
4
5
6
7
8
9
10
11
1
Retaining ring
Bearing plate
Head seal
Permeate port
Permeate port seal
Adaptor
Adaptor O ring
Thrust cone
Shell
End port
End port seal